Steel Bridge Fabrication QC QA Guide Specification

8/6/2019 Steel Bridge Fabrication QC QA Guide Specification

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AASHTO/NSBA Steel Bridge Collaboration

S 4.1 - 2002

Steel Bridge Fabrication QC/QA Guide Specification

AASHTO/NSBA Steel Bridge Collaboration

BR

IDGE

ALLIAN

CE

NATI

ONAL STEE

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Preface

This document is a standard developed by the AASHTO/NSBA Steel Bridge Collaboration. The

primary goal of the Collaboration is to achieve steel bridges of the highest quality and value

through standardization of the design, fabrication, and erection processes. Each standard

represents the consensus of a diverse group of professionals.

As consensus documents, the Collaboration standards represent the best approach to the

processes they cover. It is intended that Owners adopt and implement Collaboration standards in

their entirety to facilitate the achievement of standardization, but it is understood that local

statutes or preferences may prevent full adoption for some. In such cases Owners should adopt

these documents with the exceptions they feel are necessary.

This document establishes and defines the functions, operations, requirements, and activities

needed to achieve consistent quality in steel bridges. It is based on a cooperative approach to

achieving quality, where both the Owners and Contractors Inspectors work together with a

clear understanding of their roles and responsibilities, resulting in steel bridges completed in a

timely manner and meeting all contractual requirements

Disclaimer

All data, specifications, suggested practices presented herein, are based on the best available

information and delineated in accordance with recognized professional engineering

principles and practices, and are published for general information only. Procedures and

products, suggested or discussed, should not be used without first securing competent advice

respecting their suitability for any given application.

Publication of the material herein is not to be construed as a warranty on the part of the

American Association of State Highway and Transportation Officials (AASHTO) or the

National Steel Bridge Alliance (NSBA) - or that of any person named herein - that these data

and suggested practices are suitable for any general or particular use, or of freedom frominfringement on any patent or patents. Further, any use of these data or suggested practices

can only be made with the understanding that neither AASHTO nor NSBA makes any

warranty of any kind respecting such use and the user assumes all liability arising therefrom.

AASHTO Document No: SBFQC-1


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EXECUTIVE COMMITTEE

20012002

Voting Members

Officers:

President: James C. Codell III, Kentucky

Vice President: Tom Stephens, Nevada

Secretary-Treasurer: Larry King, Pennsylvania

Regional Representatives:

REGION I: Carol Murray, New Hampshire, One-Year Term

Patricia McDonald, Vermont, Two-Year Term

REGION II: Fred Van Kirk, West Virginia, One-Year Term

Whitting Clement, Virginia, Two-Year Term

REGION III: Henry Hungerbeeler, Missouri, One-Year Term

Mark Wandro, Iowa, Two-Year Term

REGION IV: Mike Behrens, Texas, One-Year Term

Sleeter Dover, Wyoming, Two-Year Term

Non-Voting Members

Immediate Past President: Dan Flowers, Arkansas

AASHTO Executive Director: John Horsley, Washington, D.C.

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HIGHWAY SUBCOMMITTEE ON BRIDGES AND STRUCTURES2002

Tom Lulay, Oregon, ChairmanSandra Larson, Vice Chairman

James D. Cooper, Federal Highway Administration, Secretary

ALABAMA, William F. Conway, George H. Connor

ALASKA, Richard A. Pratt

ARIZONA, F. Daniel Davis

ARKANSAS, Phil Brand

CALIFORNIA, Richard Land

COLORADO, Mark A. Leonard

CONNECTICUT, Gordon Barton

DELAWARE, Doug Finney, Dennis OShea

D.C., Donald Cooney

FLORIDA, William N. Nickas

GEORGIA, Paul Liles, Brian SummersHAWAII, Paul Santo

IDAHO, Matthew M. Farrar

ILLINOIS, Ralph E. Anderson

INDIANA, Mary Jo Hamman

IOWA, Norman L. McDonald

KANSAS, Kenneth F. Hurst, Loren R. Risch

KENTUCKY, Stephen E. Goodpaster

LOUISIANA, Hossein Ghara, Mark J. Morvant

MAINE, James E. Tukey

MARYLAND, Earle S. Freedman

MASSACHUSETTS, Alexander K. Bardow

MICHIGAN, Steve Beck

MINNESOTA, Dan Dorgan, Kevin Western

MISSISSIPPI, Harry Lee James

MISSOURI, Shyam Gupta

MONTANA, William S. Fullerton

NEBRASKA, Lyman D. Freemon

NEVADA, William C. Crawford, Jr.

NEW HAMPSHIRE, Mark Richardson

NEW JERSEY, Harry A. Capers, Jr.,

Richard W. Dunne

NEW MEXICO, Jimmy D. Camp

NEW YORK, James O'Connell, George A. Christian

NORTH CAROLINA, Gregory R. Perfettie

NORTH DAKOTA, Terry UdlandOHIO, Timothy Keller

OKLAHOMA, Robert J. Rusch, Veldo Goins

OREGON, Mark E. Hirota

PENNSYLVANIA, R. Scott Christie

PUERTO RICO, Jamie Cabre

RHODE ISLAND, Kazem Farhoumand

SOUTH CAROLINA, Randy R. Cannon, Jeff Sizemore

SOUTH DAKOTA, John Cole

TENNESSEE, Ed Wasserman

TEXAS, Mary Lou Ralls

U.S. DOT, Nick E. Mpras

UTAH, David Nazare

VERMONT, James McCarthy

VIRGINIA, Malcolm T. Kerley

WASHINGTON, Jerry Weigel, Tony M. AllenWEST VIRGINIA, James Sothen

WISCONSIN, Stanley W. Woods

WYOMING, Gregg C. Fredrick, Keith R. Fulton

ALBERTA, Dilip K. Dasmohapatra, Bob Ramsey

MANITOBA, Ismail Elkholy

NORTHERN MARIANA ISLANDS,

John C. Pangalinan

NEW BRUNSWICK, David Cogswell

NORTHAMPTON, R. T. Hughes

NORTHWEST TERRITORIES, John Bower

NOVA SCOTIA, Alan MacRae, Mark Pert

ONTARIO, Vacant

SASKATCHEWAN, Herv Bachelu

MASS. METRO. DIST. COMM., David Lenhardt

N.J. TURNPIKE AUTHORITY, Richard Raczynski

N.Y. STATE BRIDGE AUTHORITY,

William Moreau

PORT AUTHORITY OF N.Y. AND N.J.,

Joseph J. Kelly, Joseph Zitelli

BUREAU OF INDIAN AFFAIRS, Wade Casey

MILITARY TRAFFIC MANAGEMENT

COMMAND, Robert D. Franz

U.S. ARMY CORPS OF ENGINEERS-

DEPARTMENT OF THE ARMY,

Paul C. T. TanU.S. COAST GUARD, Jacob Patnaik

U.S. DEPARTMENT OF AGRICULTURE-

FOREST SERVICE, Nelson Hernandez

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Table of Contents

Introduction ..................................................................................................................................... 1

Part A General.............................................................................................................................. 2

Section 1: Definitions................................................................................................................... 21.1 Contractor ....................................................................................................................... 2

1.2 Engineer .......................................................................................................................... 2

1.3 Fabricator ........................................................................................................................ 21.4 Inspection ........................................................................................................................ 2

1.5 Owner .............................................................................................................................. 2

1.6 Quality Assurance (QA).................................................................................................. 21.7 Quality Assurance Inspector (QAI)................................................................................. 2

1.8 Quality Assurance Plan (QAP) ....................................................................................... 3

1.9 Quality Control (QC) ...................................................................................................... 31.10 Quality Control Inspector (QCI)..................................................................................... 3

1.11 Quality Control Plan (QCP)............................................................................................ 3

1.12 Spot Inspection ............................................................................................................... 3

Section 2: Responsibilities ........................................................................................................... 42.1 Team Effort ..................................................................................................................... 4

2.2 Fabricator ........................................................................................................................ 4

2.3 Owner .............................................................................................................................. 42.4 Prefabrication Meetings .................................................................................................. 5

Section 3: Qualifications and Equipment..................................................................................... 6

3.1 QCI and QAI Fabrication Inspection Experience ........................................................... 6

3.2 QCI and QAI Coatings Inspection Experience ............................................................... 63.3 Recommended Inspection Equipment............................................................................. 6

Part B Quality Control.................................................................................................................. 8

Section 4: General ........................................................................................................................ 8

4.1 Quality Control Plan........................................................................................................ 84.2 QAI Facilities .................................................................................................................. 8

4.3 Inspection and Testing Equipment.................................................................................. 9

4.4 Control of raw materials.................................................................................................. 94.5 Welding Procedures and Consumables ........................................................................... 9

4.6 Nondestructive Examination........................................................................................... 9

4.7 Nonconformance Control.............................................................................................. 10

Section 5: Certifications and Qualifications............................................................................... 115.1 QCP Requirements........................................................................................................ 11

5.2 Fabricator Certifications................................................................................................ 11

5.3 QCI Certifications and Qualifications........................................................................... 115.4 Welder/Welding Operator Qualifications ..................................................................... 11

Section 6: Documentation .......................................................................................................... 13

6.1 QCP Requirements........................................................................................................ 13

6.2 Records.......................................................................................................................... 136.3 Material Traceability..................................................................................................... 13

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Section 7: Inspection Procedures ............................................................................................... 14

7.1 QCP Requirements for Inspection................................................................................. 147.2 Preparation of Material.................................................................................................. 14

7.3 Fitting ............................................................................................................................ 14

7.4 Welding ......................................................................................................................... 14

7.5 Cambering, Curving and Straightening......................................................................... 157.6 Shop Assembly of Main Members................................................................................ 15

7.7 Cleaning ........................................................................................................................ 157.8 Coating .......................................................................................................................... 15

7.9 High-Strength Fastener Shop Installation ..................................................................... 16

7.10 Loading and Shipping of Fabricated Members ............................................................ 16

Part C Quality Assurance ........................................................................................................... 17

Section 8: General ...................................................................................................................... 178.1 Qualifications of the QAI.............................................................................................. 17

8.2 Scheduling..................................................................................................................... 17

Section 9: QAI Responsibilities ................................................................................................. 189.1 Role of the QAI............................................................................................................. 18

9.2 Interaction with the Fabricator Quality Control Inspector ............................................ 18

9.3 Interaction with the Engineer ........................................................................................ 189.4 Interpretation of the Contract ........................................................................................ 18

9.5 Fabrication Observation ................................................................................................ 18

9.6 Nonconforming Materials and Workmanship............................................................... 18

9.7 Final Acceptance of the Work....................................................................................... 19

Section 10: Documentation and References............................................................................... 20

10.1 Familiarization with Requirements............................................................................... 20

10.2 Required Documents .................................................................................................... 20

10.3 Use of Non-Approved Shop Drawings......................................................................... 2010.4 Quality Assurance Inspector Records and Reporting................................................... 2110.5 Mill Test Reports .......................................................................................................... 21

Section 11: Quality Assurance Functions .................................................................................. 23

11.1 Inspection of Raw Materials......................................................................................... 23

11.2 Inspection of Fabricated Members ............................................................................... 2311.3 Assembly ...................................................................................................................... 24

11.4 Welding......................................................................................................................... 24

11.5 Use of Approved Welding Consumables ..................................................................... 2511.6 Nondestructive Evaluation............................................................................................ 25

11.7 Coatings ........................................................................................................................ 2511.8 Bolting .......................................................................................................................... 2611.9 Final Inspection and Loading for Shipment ................................................................. 26

Commentary.................................................................................................................................. 27

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Introduction

This document is divided into three parts:

Part A: General Describes general requirements and guidelines applicable to both Ownersand Fabricators.

Part B: Quality Control Includes minimum requirements for a Fabricators quality controlprogram, with emphasis on the development and implementation of a quality control plan. The Fabricator should have one plan for all work, comprehensive enough to

address all of the points covered in Part B, but flexible enough to apply to the variety of

projects that will be fabricated. The Fabricator may want to include addenda to addressspecialty work.

Fabricators should provide a copy of their quality control plan to Owners to build the

Owners confidence in the Fabricators means and method for achieving work that will

satisfy Contract requirements. Owners may offer comments to the Fabricator about theplan as appropriate.

However, the Owner must recognize that successful implementation of the plandepends on keeping the plan simple and flexible so that it may apply effectively to the

wide variety of projects undertaken in the shop. Fabricators should not have to rewrite aplan for each project or for each Owner.

Part C: Quality Assurance Includes minimum requirements for an Owners qualityassurance program. The Owner may implement Part C as a quality assurance plan

directly. Future Collaboration work will include a Quality Assurance Practice that

will provide more detail about the work to be performed by the quality assuranceInspector.

Should conflicts arise between any requirements in this manual and the Contract documents, the

Contract documents take precedence in all instances.

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Part A General

Section 1Definitions

Terms used in this document are in accordance with the AASHTO/NSBA Steel BridgeCollaboration standards. Terms that are specifically significant to this document are defined

below.

1.1 Contractor

The Contractor is responsible for proper completion of all tasks required by the Contract.Subcontractors, including fabricators, erectors, and field painters, may be used by the

Contractor, but the Contractor retains responsibility for all material, operations, and the

final product. The Contractor should permit direct subcontractor interaction with the Ownerto expedite the project, but subcontractors must inform the Contractor of any proposed

modifications to Contract requirements accepted by the Owner.

1.2 EngineerIn this document, the Engineer is the Owners authorized representative, responsible formonitoring of the Fabricators work, and other duties and responsibilities detailed by the

Owner. The Engineer has the authority to allow exceptions to Contract document

requirements.

1.3 Fabricator

In this document, Fabricator refers to the facility(ies) performing such shop activities as

cutting, welding, drilling, punching, cleaning and painting of structural steel. Fabricator

also includes any agents of the Fabricator, such as those who prepare shop detail drawings.In some cases the Fabricator may also be the Contractor, but usually the Fabricator is a

subcontractor.

1.4 Inspection

The examination by the Owner or the Fabricator of processes and products to verify

conformance with Contract requirements.

1.5 Owner

In this document, Owner refers to the entity paying the Contractor to fulfill the terms ofthe Contract. The Owner also encompasses the following: those preparing the Contract

documents, including those responsible for the structures adequate design; and those

authorized to represent the Owner during construction, commonly called the Engineerand the Inspector. The Engineer and Inspector may be employees either of the Owner or

of professional firms contracted for the work.

1.6 Quality Assurance (QA)

Quality assurance encompasses the activities undertaken by the Owner to verify that thefinal product satisfies Contract requirements, including verifying that quality control is

performed effectively.

1.7 Quality Assurance Inspector (QAI)

The Owners representative responsible for duties specified in the Quality Assurance Plan,with the authority to accept work that meets Contract requirements.

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1.8 Quality Assurance Plan (QAP)

The formal written document (based on Part C of this standard) that establishes theactivities the QAI will follow to monitor fabrication and verify that specified criteria are

achieved.

1.9 Quality Control (QC)

The activities undertaken by the Contractor/Fabricator to ensure a product is provided thatmeets Contract requirements.

1.10 Quality Control Inspector (QCI)

A qualified employee of the Fabricator who performs inspection as defined by theFabricators Quality Control Plan.

1.11 Quality Control Plan (QCP)

The formal written document (based on Part B of this standard) prepared by the Fabricator

that describes the policies and procedures used to verify that fabricated steel will satisfy theContract requirements.

1.12 Spot Inspection

The random examination of the Fabricators processes or products for verification of

conformance with Contract requirements.

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2.3.9 The QAI will not direct the Fabricators work. However, the QAI should advise the

Fabricator to discontinue any operation that would result in noncompliance with theContract.

2.3.10 The QAI will direct all official communications to the Fabricators quality control

or management.

2.3.11 The QAI will not convey directives or personal judgments about overall shopquality or concerns about employee competence to production personnel.

2.3.12 The QAI will not divulge a fabricators proprietary information to anotherfabricator.

2.3.13 The QAI will not publish, copy or distribute any proprietary information,

documents, or forms received from the Fabricator for any purpose other than thecontractual needs of the Owner.

2.4 Prefabrication Meetings

Prefabrication meetings facilitate effective quality control and quality assurance and should

be conducted as described in section 2.4 of AASHTO/NSBA Steel Bridge CollaborationS2.1, Steel Bridge Fabrication Guide Specification.

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Section 3Qualifications and Equipment

3.1 QCI and QAI Fabrication Inspection Experience

3.1.1 In addition to the certification requirements of 5.3 and 8.2, the following minimum

years of experience in steel bridge fabrication are recommended:

Project Type

Minimum Recommended

Years of Experience

Rolled beam bridges 1 year

Welded plate girders (I sections, box sections, etc.) 2 years

Complex structures, such as trusses, arches, cable-stayed bridges, and moveable bridges

3 years

Fracture critical (FC) members 3 years

3.1.2 Inspectors who have less experience than that specified in 3.1.1 should work under

the guidance of an inspector having those qualifications.

3.1.3 Experience in rolled beam bridge inspection should not be counted towards the

experience needed for plate girders, complex structures, or fracture-criticalmembers.

3.1.4 Every inspector must be proficient with inspection of the typical fabrication

processes described in Section 7 of this document.

3.2 QCI and QAI Coatings Inspection Experience

3.2.1 Documented training in materials preparation, coatings application, and inspection

is required for the QC and QA coatings inspectors. Acceptable training includes oneor more of the following:

American Institute of Steel Construction (AISC) Application and Inspection ofSophisticated Coatings

National Association of Corrosion Engineers (NACE) - International Coating

Inspector training and Certification Program Session I: Coating InspectionTraining

Society for Protective Coatings (SSPC) - C-1 Fundamentals of Protective

Coatings for Industrial StructuresNational Highway Institute (NHI) - Bridge Coating Inspection Course No. 13079

Other training acceptable to the Engineer.

3.2.2 The QA and QC coatings inspectors should each have at least one year ofexperience in surface preparation and painting inspection. Inspectors who have lessexperience should work under the guidance of an inspector having those

qualifications.

3.3 Recommended Inspection Equipment

The following equipment is recommended for the QAI and QCI:

sling psychrometer

tape measure, 25 ft. (7 m), 1/32 or 1-mm increments.bevel gauge

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blast profile comparator or replica tape for direct measurements and a permanent record

camera, QAI to use only with the approval of the Fabricator, digital recommendeddry film thickness gauge

feeler gauges

fillet weld gauges

flashlight and spare batteriespocket metal ruler(s), 1/32 or 1-mm increments

metal tape measure, 100 ft. (30 m), 1/8-inch or 0.01-ft (5-mm) incrementsmicrometer

NDE tools, if applicable

skewed fillet weld gaugesurface roughness gauges for machine and flame cutting

(Ref. ANSI B41 or AWS C4.1-G)

temperature-indicating crayons for 30F (15C) above and below desired temperatures orsurface pyrometer

thermometers for determining air, paint and metal surface temperatures

undercut gaugemirror for examining restricted access areas (such as snipes)

tools for checking surface anomalies, coating adhesion, etc.

surface profile comparator for media (sand, shot or grit) used and/or deformable replica

tape and micrometer to check profile depth before coating.

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Part B Quality Control

Section 4General

Part B of this standard describes the minimum quality control requirements for a steel bridgeFabricator. The requirements form the basis for the Fabricators QCP.

4.1 Quality Control Plan

4.1.1 Prepare, maintain, and follow a QCP that details the QC procedures, personnel,

policies, equipment, and records used during planning, ordering, fabrication,inspection, cleaning, painting, and shipping of fabricated members.

4.1.2 The QCP shall describe the means and methods for ensuring satisfactory materials

and workmanship, including the following: procurement, maintenance and calibration of testing equipment and supplies

needed for inspection, measurement, and tests (see 4.3)

conformance of all raw materials to Contract requirements (see 4.4)preparation and use of welding procedure specifications (WPSs) and control of

welding consumables (see 4.5)

proper performance of nondestructive examination (NDE) (see 4.6)handling of nonconformances, including use of standard shop repair methods and

preapproved procedures for weld repairs (see 4.7)

use of the latest approved version of shop drawings and approved fabricationprocedures

other required means and methods described in Sections 5, 6 and 7.

4.1.3 Provide the signature of the Quality Control Manager indicating the Fabricators

intent and commitment to implement the QCP to achieve a quality product.4.1.4 Include a statement signed by the Fabricators management affirming that all

personnel will implement the QCP to achieve quality.

4.1.5 Describe the Fabricators organization, including the following:clearly established lines of authority

position titles and the names of the individuals assigned to the positions

functions and duties of each position.4.1.6 Describe the structure of the QC Department. Include an organization chart

showing the functions, duties, responsibilities, position titles and lines of authority

within the QC department.4.1.7 Describe in detail the responsibilities of QCIs, including inspecting material,

welding, assembly, coating preparation and application, and nondestructive

examination.

4.2 QAI Facilities

4.2.1 Provide and maintain office facilities for QAIs that ensure a reasonable amount of

privacy and that are clean, properly illuminated, heated or air-conditioned as

necessary, and reasonably free of shop noise, dust, and odors.4.2.2 Locate the office reasonably close to the work and provide access any time

fabrication is in progress.4.2.3 Provide a desk, chair, and secure storage (e.g., locking file cabinet) for each

inspector.

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4.2.4 Provide a telephone within the office with an outside line suitable for modem

communication.4.2.5 Provide ready access to the following:

clean, Fabricator-maintained restrooms

fax and copy machines

adequate parking.4.3 Inspection and Testing Equipment

4.3.1 Check and calibrate testing equipment in accordance with applicable standards.

4.3.2 Maintain calibration records readily accessible by the QAI.

4.4 Control of raw materials

4.4.1 Inspect all incoming raw materials.

4.4.2 Verify that no repairs have been performed at the producing mill except grinding or

welded repairs as allowed in ASTM A 6. Fracture-critical materials must notinclude any welded repairs unless authorized in writing by the Owner.

4.4.3 Verify material surface quality prior to start of fabrication.

4.4.4 Establish:inspection points (locations)

responsible party for inspection

acceptance criteriaprocedures to repair defects.

4.5 Welding Procedures and Consumables

4.5.1 Establish procedures for welding control that address the following:

responsible parties for welding of test plates, witnessing and documentingwelding parameters, preparing specimens, conducting testing, and preparing the

reports

format and use of forms, including the system for numbering or identifying

WPSsresponsible party to prepare and submit WPSs for approval

distribution of the approved WPSs in the fabricating shop

use of the approved WPSs by production and QC personnel

procedure for revision of WPSs.4.5.2 Establish procedures for control of welding consumables that address the following:

use of approved consumables

warehouse storage, including inventory and stock rotationstorage in the fabricating shop of consumables used for welding fracture-critical

and non-fracture-critical members

procedures for holding and re-drying shielded metal arc welding (SMAW)

electrodescontrol for time out of storage oven of SMAW electrodes

drying and recycling of submerged arc welding (SAW) fluxstorage of SAW flux and electrodes

storage and moisture control for flux-cored arc welding (FCAW) electrodes

storage of gas metal arc welding (GMAW) electrodes.

4.6 Nondestructive Examination

4.6.1 Establish and follow a practice that conforms to AASHTO/AWS D1.5, BridgeWelding Code, and applicable American Society of Nondestructive Testing (ASNT)

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SNT-TC-1A requirements for each NDE method employed in the shop. Include the

following:identification of a certified ASNT Level III in the applicable method(s)

a written practice approved by the Level III

ASNT Level II certification of practicing inspectors in the applicable method(s)

ASTN Level I certification of apprentice inspectors, with proper Level IIoversight

applicable code requirements for procedures.4.6.2 Where contracted services are used for NDE, ensure that the NDE agencys staff

also satisfies the applicable ASNT requirements.

4.6.3 Provide a copy of the written NDE practices to the Owner upon request.4.6.4 Make NDE training and certification records available for the Owners review.

4.6.5 Permit QAI access to the Fabricators testing facilities and records upon request.

4.7 Nonconformance Control

4.7.1 Establish and maintain an effective system for controlling nonconforming material,including procedures for identification, isolation, and disposition.

4.7.2 Establish standard shop repair methods. Standard repair welding procedures mustbe preapproved by the Owner.

4.7.3 Describe the equipment, inspections, reports, and systems necessary to segregate

materials requiring corrective work.

4.7.4 Follow these steps when a problem is identified that will require a repair approvedby the Engineer:

Determine the cause for the defect

Initiate appropriate action to prevent additional deficiencies.Submit a written proposal to the Engineer documenting the situation, suggesting

corrective actions for repairs or replacement, and, if applicable, recommendingalternate methods for subsequent production to avoid further defects.

Provide the QAI with copies of appropriate correspondence.Be prepared to provide support information if requested by the Engineer.Notify the Contractor as required.

4.7.5 Reclaim or rework nonconforming materials only in accordance with procedures

acceptable to the Owner.

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Section 5Certifications and Qualifications

5.1 QCP Requirements

5.1.1 Describe the plants level of AISC certification (see 5.2).

5.1.2 Describe certification and qualification requirements for all QCIs (see 5.3).5.1.3 Describe procedures for qualifying tackers, welders, and welding operators and for

updating and maintaining their qualification documentation (see 5.4).

5.2 Fabricator Certifications

5.2.1 Certification by AISC in the category appropriate for the type of work beingperformed is required. These categories include:

Simple Steel Bridge Structures (Sbr) - Required for overhead sign trusses, bridge

parts such as cross frames, and for un-spliced rolled beam bridges

Major Steel Bridges (Cbr) - Required for all bridges other than unspliced rolled

beam bridges

Fracture Critical (F) - Required for fabrication of fracture critical members

Sophisticated Paint Endorsement (P) - Required for shop priming or shopapplication of multi-coat systems to steel components (see applicable coating

specification for exceptions). The Society for Protective Coatings SSPC-QP 3,Standard Procedure for Evaluating Qualifications of Shop Painting Contractors,

may be substituted for the AISC Sophisticated Paint Endorsement.

5.2.2 Resolve any findings noted in the AISC exit interview reports prior to fabrication.5.2.3 Allow the Owner to review the AISC or SSPC certification records upon request.

5.2.4 If Owner acceptance is required by the Contract, allow formal review of operations

by the Owner and secure acceptance prior to fabrication.

5.3 QCI Certifications and Qualifications

5.3.1 A QCI performing welding inspection must be a Certified Welding Inspector (CWI)or equivalent, in accordance with theBridge Welding Code.

5.3.2 QCIs performing NDE must have either an ASNT Level II certification or a Level Icertification with Level II oversight for the NDE method being applied, in

accordance withBridge Welding Code requirements.

5.3.3 QCIs for coatings must be qualified in accordance with Section 3.

5.4 Welder/Welding Operator Qualifications

5.4.1 Document and maintain the following as a minimum:

the name of the department or position responsible for administering and

maintaining documentation on the qualification test programthe extent to which independent testing laboratories will be employed in

qualificationthe extent to which the QC department will be involved in qualificationthe responsible party for selecting and testing qualification plates, authentication

of test reports, and the disposition of specimens

appropriate forms and recordsfabricator method for documenting continuing experience (see the Period of

Effectiveness portion of theBridge Welding Code)

the Fabricators master list of qualified welders, welding operators, and tackwelders

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Section 6Documentation

6.1 QCP Requirements

6.1.1 Describe procedures for maintaining records (see 6.2).

6.1.2 Describe handling and control of material certifications, mill test reports (MTRs),and other records required for material or weld traceability and verification (see6.3).

6.1.3 Identify shop personnel responsible for preparation of records and reports.

6.1.4 Include sample forms.

6.2 Records

6.2.1 Maintain current and complete records of inspections, measurements, and tests.

Shop drawings or standard detail drawings may be used to document inspection.6.2.2 Make records available to the QAI during all work periods.

6.2.3 Document, report, and keep records of reportable nonconformances. (Minor

grinding, paint repairs, etc. do not require documentation.) For nonconformance

reports, include at least:the number, location, and type of deficiencies found

the nature and frequency of any repairs and corrective actions takena summary of the dispositions (corrected and approved, or rejected)

6.2.4 For items that require full or partial shop assemblies, submit to the QAI signed

reports of required measurements, indication of compliance or deviations noted, andpictures if available.

6.2.5 Provide test reports and summaries of all required NDE to the QAI.

6.3 Material Traceability

6.3.1 Review MTRs for specification compliance and for accuracy, completeness, and

specific project applicability before submittal.6.3.2 Control, identify, and reproduce MTRs for steel materials used from the

Fabricators stock or from warehouse purchases. Include the MTRs in the projectfile and provide them to the Engineer or QAI as requested.

6.3.3 Identify and trace material for primary members throughout fabrication.

6.3.4 Correlate mill-identified materials with shop drawing piece marks, and supply acopy of this information to the QAI.

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Section 7Inspection Procedures

This section includes general requirements for the QCP (7.1) and then a series of points that mustbe addressed in the QCP (7.2 through 7.10)

7.1 QCP Requirements for Inspection

7.1.1 Define quality control actions to address all points listed in 7.2 through 7.10. For

some points, quality control may require formal, documented inspection activitiesby the QCI, but for others informal monitoring activities conducted by production

personnel may suffice, provided:formal quality control is not required by Contract

production personnel are trained in acceptance criteria

production personnel are trained to be responsible for evaluating the work andnoting noncompliance items

the QCI will perform spot inspection of the work.

7.1.2 If applicable, include the inspection or monitoring frequency established by the

fabricator for all points in 7.2 through 7.10. The extent of monitoring may be lessthan 100% provided its basis considers the following criteria:

the potential effects of undiscovered deficiencies incorporated in the finalstructure

the production delays and possible problems caused by stopping processes for

inspection hold pointsthe demonstrated consistency or variability of the process

recent history of documented nonconformance.

7.1.3 Describe QCI record-keeping. For inspection, records must be detailed and must beinitialed by QCIs indicating conformance with Contract requirements. Monitoring

of quality by production personnel does not require record-keeping, but a general

record must be made of the QCIs inspections.

7.2 Preparation of Material

Identification and marking of materials

Quality of cut and sheared edgesPlate quality, with notation of surface and internal defects and repairNDE requirements and acceptance criteria for repairs

Dimensional accuracy of component parts, whether fabricated or premanufactured

7.3 Fitting

Dimensional accuracy and fit of all componentsSpecified tolerance of members prior to welding

Mill to bear and tight fit conditions

7.4 Welding

Cleanliness (absence or condition of unacceptable mill scale, rust, or contaminants)Joint preparation

Properly cleaned tack welds of suitable quality and size

Use of approved welding proceduresWeld quality and soundness requirements perBridge Welding Code

Welders qualified for process and position to be welded

Interpass cleaning and temperature

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Weld backgouging and cleaning

Fillet weld size, placement and profileGroove weld reinforcement

Grinding or finishing of welds

Avoiding, precompensating for, and correcting welding-induced distortion

Visual weld qualityPostheat as required

Storage, handling, and reuse of SAW flux and SMAW electrodes

7.5 Cambering, Curving and Straightening

Adequate blocking elevations and intervals

Following Engineer-approved calculations for locations of applied external forces or

restraints, when required by the contractSize and locations of heating patterns

Maximum temperatures and proper temperature monitoring

Controlled coolingFinal dimensions

7.6 Shop Assembly of Main Members

Dimensional accuracy of each piece (deviation from specified length, camber, sweep)

Individual member distortion, local and overall (twist, sweep, out-of-flatness of flange orweb)

Clearance or bearing fit of adjacent members in assembly

Assembly blocking dimensions and curve and camber offsets and elevationsSplice plate and secured fill plate dimensions and fit (gaps, non-parallel)

Bolt hole accuracy, including adequate edge distances

Bolt hole condition, including shape and squareness to faying surfaceMatch-marking of splice plates and correct location of all piece marks

Removal of drilling burrsPreparation and documentation of as built shop assembly report

7.7 Cleaning

Proper solvent cleaning to remove surface contamination prior to mechanical cleaning

Blast media gradation and cleanlinessVerification and documentation of required surface cleanliness and profile

Checking the compressed air system for contaminants, especially if used to remove shot

Proper functioning of automated blasting equipmentTreatment of material defects (scabs, fins, slivers) exposed by blasting, including

reblasting if necessary after repairs

Proper corner and edge treatment as required for coating system

7.8 CoatingCoating sampling by manufacturer or at the Fabricator, including witnessing and delivery

to the Engineer.

Use of Owner-approved coating batchesMaintenance of air-line oil and air moisture traps

Equipment for mixing, application, repair, film measurement, and safety

Mixing and agitationMonitoring pot life

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Application methods: spray nozzles, patterns, and sequencing for typical configurations

and for areas inaccessible for spraying (snipes, restricted)Coating repair for damage, dry spray, runs, sags, and under- or over-thickness

Control of thinning, when permitted

Ambient temperature, steel temperature, relative humidity, and dew point

Control of millage, wet and/or dry, as applicable (millage control per SSPC PA2)Intervals between coating applications

Cure assessmentDocumentation for materials used, ambient conditions, cure verification, dry film

thickness and/or wet film thickness readings, and problems and corrections

7.9 High-Strength Fastener Shop Installation

Material verification (manufacturer certifications, tensile tests, chemistries, hardness,rotational capacity test results, evidence of domestic origin) prior to installation

Fastener markings

Contact surface and hole qualityFunction and calibration of fastener tension device and torque wrench

Execution of rotational capacity testingCheck-torque for verification of proper tightening.Fastener dimensions and condition, especially proper lubrication

Use of hardened washer under the turned element during installation

Verification that all fasteners in a joint are brought to snug-tight condition prior to finaltightening

Verification that fasteners are tightened from the most rigid part of a joint towards its free

edges and that the wrench is returned to previously tightened bolts to touch up anybolts which may have been relaxed from tightening other bolts in the joint

Verification of full engagement of bolts (tip flush or beyond nut face)7.9.1 Turn-of-nut tightening

Proper snug-tight sequenceNut rotation (marks on bolt tip and nut)Verification of proper tightening

7.9.2 Calibrated wrench tightening

Torque-to-tension relationshipVerification that wrenches are set to provide proper fastener tension and are

calibrated at proper intervals

Recalibration of wrenches when necessaryMaximum allowable fastener head or nut rotation

7.9.3 Alternate Fastener Methods

Verification of load-indicating washer characteristics

Placement and interpretation of load-indicating washersSnug-tightening cycles before twist-off of control or indicator element

Procedures for snugging and full tensioning with lock pin and collar bolts

7.10 Loading and Shipping of Fabricated Members

Written acknowledgement of QA acceptance before loading

Loading, blocking, cushioning, and securing

Repair of all areas where shop protective coating has been damagedVisual inspection of all loaded members

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Part C Quality Assurance

Section 8General

Part C of this standard provides a QAP that the Owners QAIs will follow, including bothinspection personnel employed by the Owner and contracted inspection personnel acting as

agents to the Owner. The role of the QAI is defined, and general guidelines are provided for

monitoring QC procedures, fabrication personnel, qualifications, inspection status, equipmentcondition, record-keeping, and final acceptance of the work.

QAP Overview

QAIs will use this plan to verify conformance of the work with Contract requirements. The QAP

is general in nature, to meet a wide variety of conditions and differing requirements in project

plans and specifications. It is an inspection practice; it is not a part of the Contract and does notsupersede any project specifications or other job requirements.

This plan is intended to be comprehensive for typical fabrication specification requirements.

However, omission of a quality requirement in this plan does not relieve the QAI from inspectionif that requirement is part of the Contract. Contracts, through Owner standard specifications,

typically address quality assurance inspection as the prerogative of the Owner. Quality assurance

functions emphasize the review of QC work but also include independent inspections. Owner

quality assurance is not a substitute for the Fabricators quality control.

8.1 Qualifications of the QAI

8.1.1 The QAI must be qualified in accordance withBridge Welding Code requirements.

QAIs who interpret and perform NDE must be certified in accordance with theapplicable ASNT SNT-TC-1A requirements for each NDE method being used.

8.1.2 The QAI for coatings must be qualified in accordance with Section 3.8.2 Scheduling

The scheduling of inspection and other QA functions can have a significant impact on theproject. The QAI shall follow these guidelines:

Coordinate with the QCI for anticipated production scheduling to anticipate timing and

staffing needs. Discuss the progress of the work with appropriate Fabrication personneldesignated during the prefabrication conference (see 2.1.2 & 2.4.3).

Schedule inspections in a timely manner to facilitate fabrication progress, especially if

multiple shifts are used.Discuss with the Engineer whether additional presence in the shop is required.

Document problems with scheduling inspection, including inaccurate information from

fabrication personnel and production delays.

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Section 9QAI Responsibilities

9.1 Role of the QAI

9.1.1 Perform verification tests, measurements, inspection, or observations to ensure that

fabricated items conform to the Contract requirements. Although the QAI does notperform QC work, some QA activities may duplicate a portion of QC activity forverification.

9.1.2 If there are questions about a requirement or level of quality, contact the Engineer

and, if appropriate, alert the Fabricator.9.1.3 Conduct consistent inspections based on the Contract requirements while providing

guidance to the Fabricator concerning interpretation of the plan details andspecification mandates. Obtain assistance from the Engineer as needed.

9.1.4 Be familiar with the QCP to better understand the QC operations of the shop.

9.2 Interaction with the Fabricator Quality Control Inspector

9.2.1 Verify the effectiveness of the QCIs evaluation of the work.

9.2.2 Perform verification inspection after the QCI has completed inspection and testingin accordance with the QCP. However, serious problems noted at any time or stage

of fabrication must be immediately pointed out to the QCI.9.2.3 Though QA inspection may include all aspects of fabrication, the QAI must not

supersede QC, which is the responsibility of the Fabricator. If QC is not

accomplishing its role, the Engineer and Fabricator must determine the necessarycorrections.

9.3 Interaction with the Engineer

If the Fabricators inquiries involve design questions, material substitutions, alternate

fabrication methods, or items that are beyond the authority of the QAI, refer them to the

Engineer.9.4 Interpretation of the Contract

Review Contract requirements. If conflicts arise regarding their interpretation or adequacy,

seek guidance from the Engineer. Inform the QCI of the results of this discussion.

9.5 Fabrication Observation

9.5.1 Establish a pattern of regular and frequent observations during the progress of work

to verify satisfactory workmanship without delaying production or missing critical

operations.9.5.2 Coordinate verifications with the QCI and accomplish them with minimal

additional material handling by the Fabricator and with as little interference with

the work in process as possible.9.5.3 Though there are not designated points during fabrication when the suitability of

materials must be checked, problems should be discovered and addressed as early

as possible.

9.6 Nonconforming Materials and Workmanship

9.6.1 Bring any nonconformances to the attention of the Fabricator immediately upon

discovery, and, for more serious deficiencies, notify the Engineer. However, do notdirect corrective action. If the Fabricator fails to take corrective action, or continues

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to operate in an unacceptable manner, document the event, notify the QCI that the

work may be rejected and contact the Engineer.9.6.2 Verbal notification of nonconformance is usually sufficient, but if halting an

operation must be recommended, convey this in writing. Before taking this action,

discuss the situation with the QCI and obtain direction from the Engineer. If the

Fabricator continues the operation after receiving the recommendation to cease, allsubsequent production by that method and the Owners potential rejection without

QA inspection will be at the Fabricators risk.9.6.3 For significant problems, the Fabricator must submit a written proposal concerning

the issue, providing documentation of the situation and proposed actions to address

the issue. When the Fabricators proposal is received, reply or, for more seriousdeficiencies, forward the problem to the Engineer. For such serious deficiencies, the

Fabricator may write directly to the Engineer, Contractor, or both, as directed, and

send a copy to the QAI.9.6.4 When the Engineers approval is required for a repair, review and confirm the

Fabricators proposed methods of repair and description of the existing material

conditions. Seek guidance from the Engineer for clarification when necessary.Follow up to verify that all required corrections and applicable NDE have been

accomplished.

9.7 Final Acceptance of the Work

9.7.1 When fabrication is complete and inspection results demonstrate that all Contractrequirements for the Fabricator have been satisfied, the materials are conditionally

accepted, with final acceptance at the jobsite, in accordance with the Owners

customary practice.9.7.2 Affix the Owners stamp or mark on the piece (or a group of parts bundled or

contained together), if required, during preparation of a member/component forshipping, indicating that a representative of the Owner has inspected and accepted

the work. Presence of this stamp does not relieve the Contractor of responsibilityfor proper loading, shipping, final fit, and acceptable final condition of the memberor component.

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Section 10Documentation and References

10.1 Familiarization with Requirements

10.1.1 Become familiar with applicable portions of the Contract documents covering the

work to be inspected. Study the plans and specifications before fabricationcommences to provide ample opportunity to coordinate with the Engineer.

10.1.2 Have thorough knowledge of the following references:applicable current standard specifications, supplements, special provisions,

special specifications, and addenda

approved shop drawings (see 10.3)

applicable provisions of the AREMA Manual for Railway Engineering, ifrequired for the project

AASHTO/AWS D1.5,Bridge Welding Code

fabricators QCP.10.1.3 Be familiar with the following references:

AWS D1.1, Structural Welding CodeAWS A2.4, Symbols for Welding and Nondestructive Testing

AWS A3.0, Standard Welding Terms and Definitionsapplicable ASTM or AASHTO specifications

applicable coating test methods

applicable SSPC Specificationsprefabrication meeting minutes, if any

metrication conversion tables, if required.

10.2 Required Documents

Acquire the following documents:

MTRs for material used in fabrication

list of qualified welders, welding operators, and tack weldersapproved WPSsapproved welding procedure qualification records (PQRs)

copy of approved nondestructive testing procedures

list of qualified NDE technicians for the projectNDE reports for all work on this project that has been inspected and accepted by NDE

project record log sheets.

10.3 Use of Non-Approved Shop Drawings

Fabrication should proceed only with approved shop drawings. However, if the Fabricator

must proceed prior to receipt of approved shop drawings (performing work at their own

risk), ensure that the Engineer is aware of this activity and proceed with preliminary or

basic QA functions using non-approved shop drawings. Later, verify notes againstapproved drawings.

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10.4 Quality Assurance Inspector Records and Reporting

10.4.1 Maintain a narrative report for each project, as directed by the Owner. The report

should either be legibly hand-written in a permanently bound book, or bemaintained in an electronic log with automatic date and time recording. Record the

Fabricators activity on the work inspected, including both positive and negative

comments, suggestions given to the Fabricator, and any agreements made. Makeentries as soon possible after the events or conversations.

10.4.2 The Engineer may require a periodic status report. If so, include information about

the status of the work performed, shop activities, and other events of interest to theEngineer. Number the reports consecutively until completion of the work, with the

last report noted final.

10.4.3 Make notes, letters, faxes, reports, and memoranda clear and brief, and keep themon file.

10.4.4 Do not make or release photographs or digital images without the Fabricators

approval.10.4.5 Documentation is not a substitute for appropriate dialogue with the Fabricator, but

should provide a record of important discussions. Sign on-site correspondence as itsoriginator. Correspondence may also be sent to the Fabricator from the Engineersoffice. In some cases, the QAI is more familiar with the events or issues and

therefore should review and comment on draft copies of the Engineers

correspondence.

10.5 Mill Test Reports

10.5.1 Verify use of proper materials by checking a copy of the MTRs when the material

arrives and by monitoring heat numbers during fabrication until the material is

joined into a piece-marked item.10.5.2 Obtain MTRs from the Fabricator in accordance with the Owners customary

practice, including the number of copies and when and to whom MTRs should besubmitted.

10.5.3 Periodically verify the following information on MTRs:

product description (specifications, grade, H or P testing frequency)

chemistry

physical test results, including Charpy V-Notch when applicable

applicable Buy America certification requirementsheat number

certification signature (Quality Control Department and Notary, when required)

This information will be checked by the Fabricator.

10.5.4 Do not accept material if the Fabricator cannot furnish appropriate certifications to

establish compliance with the required material properties and Buy Americarequirements, if required in the Contract.

10.5.5 Maintain a record of heat number identification for main members.10.5.6 Accept structural steel based on MTRs. Miscellaneous hardware or other associated

products may be accepted based on certifications of compliance.

10.5.7 The Owner may require additional independent physical and chemical tests of thematerials properties. If so, these tests must be performed as soon as practical, and

prior to fabrication. If the independent tests indicate noncompliance, do not allow

use of the material until an agreement is reached between the Owner and the

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Fabricator as to its acceptability. Bring such noncompliance to the attention of the

QCI for evaluation and disposition.10.5.8 MTRs and laboratory reports must be accepted by the Owner before the material

can obtain final approval. Verify compliance of MTRs with the requirements of the

relevant ASTM or AASHTO specification (see 11.1.1).

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small parts properly packaged or otherwise secured against loss or damage in transit

loose pieces fastened in place for shipmentapplication of rust-preventive material when required, and covering to prevent

contamination of painted surfaces.

11.3 Assembly

11.3.1 Periodically observe laydowns and shop assembly.11.3.2 Verify the Fabricators geometry control methods and measurements. For full or

partial shop assemblies, receive the QCIs signed reports of measurements for the

Owners records. For full assemblies, photographs should also be included in theQAIs report (see 10.4.4).

11.4 Welding

11.4.1 Monitor these criteria prior to welding:

appropriate equipment in acceptable condition and periodically calibrated perQCP

proper functioning of drying and baking ovens

Qualified welders, welding operators, and tack weldersappropriate, approved welding procedures for detailed joint

joint details, including root face and opening, bevel angle, and alignment of parts

within appropriate welding code tolerancesproper application of extension tabs (run-on and run-off)

cleanliness of surfaces to be welded

proper condition and storage of welding consumablessize, quality and location of tack welds.

11.4.2 Monitor these consumable-handling criteria:

storage, condition, and exposure times of welding consumablesre-drying and recycling limits.

11.4.3 Monitor these criteria during welding:following approved welding procedure specifications (WPSs): amperage,

voltage, speed of travel, electrode extension, shielding gas flowrate, and preheat,

interpass, and/or post-heat temperatures within applicable welding code andWPS tolerances

workmanship of individual welders

use of proper repair procedures for fabrication errors, including, when required,the Engineers approval

weld starts and stops, securing and removing runon and runoff tabs, stopping

short of snipes or plate edges, and ending without craters11.4.4 Monitor these final weld quality criteria:

size, profile, and contour of fillet and groove welds

no defects in welds or parent metalaccurate interpretation by QCIs for the acceptance or rejection of welds

cleaning and backgouging of welds, including thorough removal of unsound

metal and gouging contamination (copper, carbon).

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11.5 Use of Approved Welding Consumables

11.5.1 Review the consumable manufacturers certificate of conformance maintained by

the Fabricator for all consumables used. Obtain copies for project file if required byOwners policy.

11.5.2 If the Owner maintains a list of approved electrodes, verify that all consumables

used by the Fabricator are on the list.

11.6 Nondestructive Evaluation

11.6.1 Review and approve the qualification documentation of those performing NDE for

the Fabricator.11.6.2 Periodically witness NDE, review the test results, and verify that reports are

complete and legible.

11.6.3 For radiographic testing (RT), conduct the following activities:

Interpret test results in accordance with Contract requirements.

Verify that final edges may be properly interpreted. (If the plate will be cut after

RT, the final edge may be within the plate on the RT film.)

Verify proper application of edge blocks if necessary (plate edge is final edge instructure).

Verify that each radiograph represents a unique section or piece by comparing

punch marks or other approved methods of marking the work and correspondingmarks on the film.

11.6.4 Periodically observe or conduct, if necessary, ultrasonic testing (UT) to verify the

Fabricators NDE results. The QAI will determine intervals for observation ofverification testing unless otherwise directed by the Engineer.

11.6.5 For magnetic particle testing (MT), conduct the following activities:

Periodically observe the application and interpret the results of MT performed onprimary members to verify that they satisfyBridge Welding Code requirements.

On ancillary, secondary or miscellaneous items, periodically observe andinterpret MT when required by the Contract.

Observe MT when needed to verify visual findings.

Observe and interpret MT applied to evaluate removal of defects and weldedshop repairs for base metal and deficient welds.

11.6.6 For liquid penetrant testing (PT), periodically observe technique and interpret

results.

11.7 Coatings

11.7.1 When sampling:

Coordinate coating sampling in the shop with the Fabricator.

Conduct sampling as early as possible.

Witness sampling, including mixing or stirring if required for uniformity.Ensure that the required samples are delivered to the Owner in suitable

containers.11.7.2 If the Owner maintains a list of pre-tested, pre-approved coatings so sampling is not

required, check the list to ensure that the actual batches or lots of the paint to be

used are acceptable.11.7.3 If the Owner obtains coating samples directly from the manufacturer, and the

batches are approved prior to shipment to the Fabricator or jobsite, verify that the

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batch numbers received correspond to the approved list, and, if applicable, that

approval stamps are present.11.7.4 Prior to coating application, verify the following:

Coating containers are properly marked with a batch number.

Batches have been properly strained and mixed (note when pot life initiates).

11.7.5 Do not accept coated girders until the Owners lab accepts the coating.11.7.6 For coating application inspection, verify the following:

proper cleaning and surface preparation of base metal prior to coatingapplication of coating in accordance with manufacturer and/or Contract

requirements

adequate curing of each coat as demonstrated by the prescribed test and, whenmulti-coat systems are used, prior to the application of subsequent coats

thickness of coating, wet or dry, as specified for each system and type

sufficient drying of coating prior to loading for shipmentabsence of dry spray, runs, sags and other defects

proper coating of inaccessible and limited access areas

proper treatment of faying surfaces.11.8 Bolting

11.8.1 If fasteners to be tested by the Owner are sampled at the Fabricators facility,

witness and document sampling of components for fastener assemblies in

accordance with the Owners practice.11.8.2 Verify that all fasteners are properly stored and segregated.

11.8.3 When fasteners are installed in the shop, ensure that installation and verification

testing procedures are properly followed.11.8.4 Witness the rotational capacity and verification testing for shop-installed high-

strength fasteners.

11.9 Final Inspection and Loading for Shipment

11.9.1 When all work is complete, conduct a final visual examination of the work.

11.9.2 The QCI will provide copies of reports covering the materials to be shipped. Verify

that all data are correct.11.9.3 Randomly observe handling and loading of the work to verify that the methods and

supports used will prevent significant damage during shipping.

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Commentary

C1.2 In fabrication, there are two distinct engineering roles played by the Owner. One is thedesigner, and the other has responsibility for accepting fabricated members. In general, the

fabrication engineer works with the QA inspectors to ensure the quality of fabricated work, and

can also judge acceptability of work not fully satisfying the contract, such as material or weld

defects. The designer must be consulted if there are to be any changes that may affect thebehavior of the structure.

Open communication between the Fabricator, the fabrication engineer, and the designer is

important; however, communication between the designer and the fabrication engineer must becoordinated to avoid confusion. A good rule of thumb is that prior to shop drawing submittal, the

Fabricator should communicate directly with the designer to resolve any technical questions, so

that resulting agreements will be reflected in the shop drawings. After the shop drawings havebeen approved, the Fabricator should communicate with the fabrication engineer because the QA

and QC inspectors will be checking the work based on the shop drawings and they must be

informed of all changes.

C2.1 All parties involved in fabrication must have a common objective: to provide steel meetingall contract requirements in a timely fashion with minimum repairs. To this end, the Owner and

the Fabricator should work together in a cooperative spirit, and develop relationships based on

mutual respect and trust.

C2.3.12 The Fabricator should inform the QAI when information is proprietary to avoid

confusion. In general, the QAI should respect the fabricators intellectual property and not

discuss operations with other fabricators, even if the information is not proprietary.

C3.1 The objective of this provision is to ensure that the inspector has the experience andknowledge necessary to effectively fulfill the positions responsibilities. The amount of

experience needed varies with the complexity and criticality of the work. Though these time

periods should be sufficient to familiarize the inspector with steel bridge fabrication, more timemay be needed to ensure that the inspector has the capability to carry the full responsibility of the

inspector.

These time limits normally apply to the inspector with full responsibility for acceptance of the

work. For the fabricator, this may include the QC manager and lead inspectors in each work area(preparation, welding, painting). For the Owner, this is the projects lead inspector who provides

final acceptance of the work. These recommendations should not preclude inspectors with less

experience working under the guidance of more qualified inspectors.

These time limits are recommended and not required because the amount of time it takes for aninspector to be ready to carry the full responsibility for inspection varies from person to person.

The Engineer or Fabricator should carefully consider the integrity and the abilities of theindividual before assigning responsibilities for inspection. The time needed for an individual togain adequate competency could be more or less than the recommendations.

C3.1.3 Usually rolled beam bridges are not very complex and so the guide recommends that

experience with rolled beams not be counted. However, some rolled beam bridges, especially

continuous-span bridges, are rather complex, and experience on such structures may beconsidered.

C4.4.1 Material quality should be verified before use. However, not all surfaces of material areaccessible during receipt inspection, and the Fabricator does not need to move materials just for

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this inspection. Evaluation of surface quality continues through the fabrication cycle and is

performed by production as well as inspection personnel.

C4.5.2 Approved consumables are either on the Owners list of approved consumables or as permitted in the Contract, based on Procedure Qualification Test Report (PQR) test data and

certificates of conformance from the consumable manufacturer.

C4.7.4 When problems are found during fabrication that require the involvement of thefabrication engineer or the designer, questions should be submitted through the fabrication

engineer. There should be only one Owner representative who coordinates all corrections and

changes to the work. However, when the designer needs to be involved, the fabrication engineershould coordinate direct, informal communication between the fabricator and the designer to

facilitate a quick resolution to the problem.

C5.2 The Collaboration requirements for the Fabricators QCP are intended to be compatible

with the AISC certification program requirements. QCP requirements should not contradict theAISC certification requirements; duplicate work is not desired where the Collaboration and

AISC programs have like requirements.

C5.4 Under theBridge Welding Code, qualification of welders is the Fabricators responsibility.

The Owner is not required to provide or approve welder qualification testing.

C6.2.1 For projects that are small or non-complex, Fabricators sometimes prefer to keep recordson shop drawings rather than creating additional forms for documentation. This practice is

acceptable as long as all pertinent information can reasonably be maintained and conveyed.

C7.1 There are many ways a Fabricator can help ensure quality. This section divides Fabricatoractivities into two parts: (1) formal activities, which include the various functions of the QC

department, including those stipulated by Contract, such as NDE; and (2) informal quality

control, such as production personnel checking their own work. Detailing the formal QCactivities is a primary purpose of the QCP, but it does not need to stipulate the informal activities

of the production personnel. The QCP should reflect the fact that production personnel areresponsible for the quality of their work and should be mindful of their work, but does not need

to detail production personnel activities to ensure quality.

C7.7 Though corner grinding or breaking has long been a requirement, recent research reflects

that corner grinding is not needed for fatigue performance, nor for proper performance of manycoatings. The inspector should check the Contract for any specific corner-grinding requirements

and inspect the work accordingly.

C8.2.1 QAIs should be knowledgeable and appropriately trained or certified to properly conduct

their duties. The QAI routinely observes and reviews the work performed by the fabricator,including NDE, on behalf of the owner. If the QAI performs NDE or interprets the NDE results

provided by the fabricator, the QAI should be certified in the NDE method. Radiographic testing(RT) is an exception, since the QAI may be able to interpret an RT film without being qualifiedto perform RT.

C8.3 Schedule coordination between the QAI and the shop is important. Owners want to be

present for important production events, but it may be unnecessary and impractical for the

Owner to be present during all production. The plant should provide sufficient information to theOwner about the production schedule, and the QAI should make every effort to be present when

needed in the plant.

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C9.1 In steel bridge fabrication customary practice, quality assurance (QA) generally refers to

the role performed by the Owners inspectors, and quality control (QC) is the responsibility of,and therefore performed by, the Fabricators inspectors. Generally speaking, the Fabricator

performs QC to be sure the work is good. Some QC is specifically prescribed by the Contract,

but beyond the prescribed work there are many other QC functions that must be performed to

ensure that the bridge is correctly fabricated. QA work is not intended to be as detailed as QCwork. An important QA function is ensuring that the QC department is properly checking,

documenting and correcting work. However, this does not preclude inspection by the QAI, andthe QAI should perform some actual measurement and evaluation of the work. However, the

Owner and Fabricator must be careful to ensure that the QAI does not take on the role of the

QCI. This can occur especially in less experienced shops without a fully developed andexperienced QC department. Knowing that the QAI will be checking the work, the Fabricator

may feel that the QA check will be enough and QC is not needed. This is erroneous, both

because quality is the Fabricators responsibility, and, perhaps more importantly, because to betruly effective QC must be proactive and involved in the work from the start and throughout

production.

C9.4 An unrealistic or too literal interpretation of the specifications can disrupt the project.

C9.6 The resolutions for some problems originate elsewhere, but all issues should be routed

through the fabrication engineer, particularly after shop drawings are approved. In cases wherethe designers input or approval is needed, the Fabricator may send advance copies of proposed

resolutions directly to the designer, but the formal submittal should still be through the

fabrication engineer. The designer should reply directly to the fabrication engineer, who in turnreplies to the Fabricator and ensures that everyone involved is informed of the resolution.

C10.3 Fabricators should have approved shop drawings before fabrication begins, but often

shop drawings are not yet approved when the Fabricator wants to begin work. Shop drawings

should be returned within a reasonable amount of time (see review time recommendations in

AASHTO/NSBA Steel Bridge Collaboration G1.1, Shop Detail Drawing Review/ApprovalGuidelines) but Owners sometimes take much longer, even several months. In such cases

Fabricators may request approval to begin fabrication without having approved shop drawings,

taking responsibility for any changes. Because holding up the Fabricator may delay progress inthe field, Owners should allow the Fabricator to proceed, provided the Fabricator has submitted

the shop drawings and provides copies of the submitted drawings to the QAI. The QAI should

use the Fabricators drawings as submitted until the approved drawings are provided. Then the

QAI and QCI should coordinate with the Fabricators detailer to define any drawing revisionsand verify that changes are incorporated into the work.

C11.4.2 The QAI must ensure that approved welding procedures are followed. This includes

observing the QCI periodically monitoring the current and voltage. The QAI should be aware

that voltage varies over the length of the welding leads and that welding machine gauges oftencannot be trusted. Therefore, current and voltage should be verified as close to the work as

possible using calibrated ampere and volt meters. Travel speed and wire feed speed should bechecked using a tape measure or ruler and a watch with a second hand.